Polymers of difluoroketene dialkyl acetals



United States Patent US. Cl. 26087.5 13 Claims ABSTRACT OF THE DISCLOSURE Polymers of difluoroketene dialkyl acetals of the formula /OR CF2=C in which R is an alkyl containing up to 30 carbon atoms can be made by homopolymerizing or copolymerizing the monomer with TFE or other ethylenically unsaturated monomers in solution, emulsion or in bulk, at temperatures ranging from 80 C. to 200 C., in a sealed container with an inert atmosphere and in the presence of free radical initiator.

This invention relates to difluoroketene dialkyl acetals, polymers thereof, and to the preparation of both. This invention also relates to novel intermediates used in preparing the difluoroketene dialkyl acetals.

The novel monomers of this invention are difiuoroketene dialkyl acetals, which are represented by the formula wherein each R is the same or different alkyl group. The carbon content of the alkyl groups is not critical and each group may contain up to 30 or more carbons. How-' ever, for convenience and availability of reactants, the alkyl groups are preferably of l to 8 carbon atoms each, and most preferably, each alkyl group is methyl. EX- amples of R groups include methyl, ethyl, propyl, hexyl, decyl, octadecyl, and the like.

The monomers are prepared by reacting perfiuoropyruvyl fluoride or its dimer with an alcohol (ROH) in the presence of a base which consumes the HF produced to form the novel intermediate, the alkyl ester of 2- hydroxy-2-alkoxy-3,3,3-trifiuoropropanoic of the formula treating this intermediate product with an alkali metal alkoxide and dialkyl sulfate to form the novel intermediate, the alkyl ester of 2,2-dialkoxy-3,3,3-trifluoropropanoic acid of the formula 3,480,603 Patented Nov. 25, 1969 The invention also includes polymers of the difiuoroketene dialkyl acetals, including homopolymers and copolymers with tetrafiuoroethylene. These polymers thus contain structural units of the formula wherein R is as defined as above.

The preparation of the novel intermediates and monomers can be depicted as follows:

I II I CF anon MOR orrt l t fion ME lMOR alternate route: II

l RzS O 4 III lMOH

OR OR 0 M represents an alkali metal, such as lithium, sodium, potassium, cesium and the like.

The perfluoropyruvyl fluoride is preferably added slowly to a mixture of the alcohol and the base MOR at about C., and the mixture brought to room temperature to produce compound I which is the first mentioned novel intermediate of this invention. However, temperatures ranging from about 80 C. to about 40 C. can be employed. Pressure is not critical.

Compound I is then added to an equivalent amount of the alkoxide MOR, preferably dissolved in an alcohol ROH, over a temperature range of 80 C. to 40 C., and then heated at 20-60 C. to produce compound II. After cooling compound II to -20 to +20 C., a dialkyl sulfate is added to produce compound III which is the second mentioned novel intermediate of this invention. Compound II is also novel but is not claimed herein.

If two equivalents of the alkoxide are employed initially as shown, compound II is obtained, and the dialkyl sulfate can be added directly to the reaction pot to obtain compound III.

The dialkoxy ester III can then be saponified with an alkali metal hydroxide by well-known procedures to obtain the alkali metal salt of 2,2-dialkoxy-3,3,3-trifluoro propionic acid (compound I), for if an excess of the alkoxide is present when compound II is formed, degradation of compound II may occur upon heating. The amount of the alkoxide can be controlled more easily by isolating compound I before adding the second equivalent of the alkoxide.

Instead of using an alkali metal alkoxide to remove HF, any base or HP scavenger can be used to react with it. Such scavengers include, e.g., alkali metal fluorides, such as sodium fluoride; amines, such as triethyl amine, and the like. The dimer of perfluoropyruvyl fluoride can be used in place of perfluoropyruvyl fluoride to form the acetals of this invention.

Difluoroketene dimethyl acetal can alternatively be prepared by reacting sodium methoxide with tetrafiuoroethylene in a solvent inert to the reactants and products at temperatures of -50 C. The difluoroketene dialkyl acetals can be isolated by fractional distillation.

The compounds, alkyl ester of 2-hydroxy-2-alkoxyand 2,2-dialkoxy-3,3,3-trifluoropropanoic acid, are new classes of fluoro-hydrocarbon compounds. These compounds are stable, high boiling liquids. They are useful, for example, as intermediates, one to prepare the other in the order named and to ultimately prepare corresponding difluoroketene dialkyl acetals as previously described. Generally, the ester alkyl group will correspond to at least one of the 2-alkoxy substituents. Different alkoxy substituents for compound III and its acetal derivative are obtained by employing mixed alcohols to react with perfluoropymvyl fluoride or by employing a dialkyl sulfate having a different alkyl group than the R group of the alcohol.

The difluoroketene dialkyl acetals readily homopolymerize. Therefore, it is desirable to isolate the monomer in a slightly impure form to prevent inadvertent homopolymerization.

Both homoand copolymerization of the monomer is carried out by free radical initiation. The polymerization is carried out in conventional fashion; namely, in solution, emulsion, or in bulk, at temperatures ranging from '--80 C. to +200 C., in a sealed contained with an inert atmosphere and in the presence of a free radical initiator. The polymerization time, temperature, the particular initiator and its amount, the presence or absence of chaintransfer agents can all be varied in conventional manner to obtain the desired degree of monomer conversion and molecular weight. Pressure is not critical.

Suitable initiators are those used for the free radical polymerization of unsaturated compounds. A perfiuorinated initiator, such as nitrogen difluoride, N F or perfluoropropionyl peroxide, is preferred to avoid terminal groups containing hydrocarbon residues. Other initiators include peroxides, hydroperoxides, peracids, peresters, and azo compounds. In the case of peroxides and hydroperoxides, the preferred initiators have at least one tetriary carbon atom attached directly to the peroxide grouping, for example, di-a-cumyl peroxide, u-cumyl hydroperoxide, di-t-butyl peroxide, and the like. Other suitable initiators include benzoyl peroxide, lauroyl per oxide, bis-p-chlorobenzoyl peroxide, bis-2,4-dichlorobenzoyl peroxide, di-l-naphthoyl peroxide, t-butyl perbenzoate, cyclohexyl hydroperoxide, diisopropyl peroxy dicarbonate, acetyl peroxide, azo bis isobutyronitrile, and the like. Polymerization can also be initiated by molecular oxygen or ultraviolet radiation.

The homopolymer is a thermoplastic, normally a high molecular weight solid and can be formed into shaped articles and tough, stiff films which are useful in commerce in the manner as other plastics fabricated into such shapes. The monomers of this invention can be also copolymerized with the tetrafiuoroethylene by free radical initiation.

The following examples are illustrative of the monomers and polymers of this invention. Parts and per cents are by weight unless otherwise indicated.

EXAMPLE I Methyl ester of 2-hydroxy-2-methoxy-3,3,3-trifluoropropanoic acid Into a 300 ml. flask equipped with a magnetic stirrer, distillation column and head, was placed a solution of 27 g. of sodium methoxide in 150 ml. of methanol. The contents of the flask where chilled to 80 C. and 72 g. of perfluoropyruvyl fluoride dimer added slowly. The mixture was brought to room temperature and then heated to remove the methanol. The methyl ester of 2-hydroxy- 2-methoxy-3,3,3-trifluoropropanoic acid was obtained by distillation, B.P. 60 C. at 15 mm., in 88% yield.

Analysis.-Calcd. for C H F O C, 31.9; F, 30.3; H, 3.7. Found: C, 32.0; F, 29.2; H, 3.8.

Alternatively, methanol was added to the perfluoropyruvyl fluoride dimer in a 4:1 molar ratio at C. and the stirred solution brought to room temperature. One mole of sodium fluoride was added to react with the HF which was formed and the methyl ester of Z-hydroxy- 2-rnethoxy-3,3,3-trifluoropropanoic acid was obtained by distillation.

EXAMPLE II Methyl ester of 2,2-dimethoxy-3,3,3-trifluoropropanoic acid A 500 ml. flask, equipped with a magnetic stirrer, a distillation column and a head, was charged with 250 ml. of methanol. 36 g. of sodium methoxide was added with stirring and the mixture cooled to 0 C. 107 g. of the methyl ester of 2-hydroxy-2-methoxy-3,3,3trifluoropropanoic acid was then introduced. The mixture was brought to room temperature and after 30 minutes, the temperature was raised to 40 C. and stirring continued for another 2 hours. The mixture was cooled to 0 C. and 84 g. of dimethyl sulfate introduced. Then the reaction mixture was heated and about 200 ml. of methanol was distilled off. The resulting reaction mixture was cooled to 0 C. and about 200 ml. of an ice water mixture added. After separation in a separatory funnel, the product was extracted three times with 100 ml. portions of cold Water, dried over anhydrous sodium sulfate and then distilled to yield 104 g. of the methyl ester of 2,2- dimethoxy-3,3,3-trifluoropropanoic acid, B.P. 74 C. at 31 mm.

Analysis.-Calcd. for C H O F C, 35.64; H, 4.46; H, 4.46; F, 28.22. Found: C, 36.61; H, 4.46; F, 27.97.

EXAMPLE III Difluoroketene dimethyl acetal Into a 100 m1. flask equipped with a magnetic stirrer and short column, was placed 5.6 g. of potassium hydroxide in 10 ml. of water and 30 ml. of methanol. The solution was stirred and 20.2 g. of the methyl ester of 2,2-dimethoxy-3,3,3trifiuoropropanoic acid added slowly. After the exothermic reaction, methanol and Water were removed from the resulting potassium salt by evacuating flask by gentle heating in vacuo.

2 g. portions of the dried potassium salt were then pyrolyzed at 260-300 C. to yield difluoroketene dimethyl acetal, B.P. 78.5 C., M.P. 67 C., in -99% yield. Both F and proton NMR spectra as well as infrared spectroscopy confirmed the structure.

EXAMPLE IV Homopolymerization of difluoroketene dimethyl acetal Copolymerization of difluoroketene dimethyl acetal and tetrafiuoroethylene Into a 30 ml. Carius tube was charged 15 ml. of tbutanol, 0.01 g. of azobisisobutyronitrile, 1 ml. of di-. fluoroketene dimethyl acetal, and 3 ml. of tetrafiuoro- EXAMPLE VI Ethyl ester of 2-hydroxy-2-ethoxy-3,3,3-trifiuoropropanoic acid (A) Into a flask equipped as in Example I was placed 35 gm. of sodium ethoxide and 150 ml. of absolute ethanol. After the sodium ethoxide dissolved, the solution was chilled to -80 C. and 72 gm. of perfiuoro pyruvyl fluoride dimer was added. The mixture was warmed to room temperature and the product was distilled at 2 mm. pressure and 38 C. 110 g. of the abovenamed ester were obtained. Infrared spectroscopy showed absorbancies (in at 2.9, 3.4, 5.75, 6.8, 6.9, 7.3, 8.0, 8.4, 8.7, 9.0, 9.8, 10.1, 11.6 and 13.6.

(B) Into a flask equipped as in Example I, was placed 23 g. of sodium metal and 250 ml. of absolute ethanol, and 144g. of perfluoropyruvyl fluoride dimer was added at -80 C. After warming to room temperature, the product was distilled at 2 mm. pressure and 38 C. The product was identified by F and proton NMR and by infrared analysis.

' EXAMPL'E VII Ethyl ester of 2,3-diethoxy-3,3,3-trifluoropropano1c acid 5.75 g. of sodium metal and 220 ml. of absolute ethanol were stirred in a 300 ml. flask equipped with a side arm, distillation column and head, and the flask cooled to 80 C; whereupon 54 gm. of the product of Example VI were slowly added. The stirred solution was heated to about 50 C. for about 4 hours and then chilled to 80 C. Diethyl sulfate was added and the mixture was then brought to room temperature. After distillation at about 34-35 C. at atmospheric and slightly below atmospheric pressure to remove impurities, ice was added and the ethyl ester named above was separated.

After drying over anhydrous sodium sulfate, the product was distilled at 35 C. and about 1 mm. pressure.

Analysis.Calcd. for C l-1 F 0 C, 44.26; H, 6.19; F, 23.24. Found: C, 44.10; H, 6.15; F, 23.70.

EXAMPLE VIII Difluoroketene diethyl acetal 22.7 g. of the product of Example VII were added to 6.5 gm. of potassium hydroxide in a mixture of 10 ml. of water and 30 ml. of ethanol at -80 C. The mixture was warmed to room temperature and stirred for 3 hours. The liquids were stripped off under vacuum and the potassium salt dried at 60 C. 22.2 g. of the salt were obtained.

Samples of the potassium salt were pyrolyzed at 410 C. and 420 C., respectively, in a pyrolysis train under vacuum. The product was collected in a Dry Ice bath. Infrared and NMR data confirmed the structure corresponding to difluoroketene diethyl acetal, B.P. 108 C.,

M.P. 149 C.

Upon standing in a closed glass tube for about 2 weeks, the monomer forms a white solid polymer. Infrared analysis of the polymer showed major absorbancies (in at 3.4-3.5, 5.6, 6.8, 6.9, 7.2, 7.3, 8.3-9.3, 9.7, 11.1, 12.0, and 12.4.

Analysis.-Calcd. for C H O F F, Found, 24.71.

EXAMPLE -IX In a 6 ml. Carius tube there was placed 2.5 ml. of CF =C(OC H and 0.03 g. azobisisobutyronitrile. The tube was chilled to -190 C., evacuated and flushed with nitrogen three times and sealed. After standing 16 hours at room temperature 1.1 g. of a white polymer was obtained. This was pressed at 200 C. into a colorless, transparent film which exhibited the same infrared spectra as the homopolymer prepared in Example VIII.

EXAMPLE X Into an evacuated 30 ml. Carius tube at C., there was charged 10 ml. of CCI FCF CI, 0.5 ml. CF =C(0C H 4.0 ml. (at 80C.) CF =CF and 0.02 g. (C F COO) The tube was sealed. and allowed to stand 16 hours at room temperature and then heated 16 hours at 75 C. There was obtained 1.0 g. of a white solid copolymer of TFE and CF =C(OC I-I which by elemental analysis contained 88 wt. percent TFE units and 12 wt. percent CF =C(OC H units.

EXAMPLE XI Difluoroketene dimethyl acetal Into a 500 ml. flask equipped with a magnetic stirrer and entry tube was charged 150 ml. of diglyme and 32.4 g. of sodium methoxide. The stirred mixture was chilled, evacuated and then brought to room temperature. Tetrafluoroethylene gas was run into the mixture over a period of 5 hours at room temperature; 27 g. reacted. The prod ucts were distilled from the mixture at low temperatures and subatmospheric pressures and then subjected to vapor phase' chromatography. Yields based on the tetrafluoroethylene were 50.5% CH OCF=CF 44.1% dimethoxy fluoroethylene as a mixture of cis, trans isomers and CF :C(OCH By NMR and infrared spectroscopy the CF =C(OCH component amounted to between 4 and 6% of the dimethoxy fraction.

The perfluoropyruvyl fluoride reactant can be prepared by treating hexafluoropropylene epoxide with a carbonyl compound of the formula YCOY' wherein Y is a hydrocarbon and Y is a hydrocarbon or hydrogen, e.g. benzophenoue or benzaldehyde, at a temperature of between and 300 C. For example, in a 500 ml. three-necked flask containing a gas inlet tube, a stirrer and a gas outlet tube, is placed 200 g. of benzophenone. The gas outlet tube is connected to 2 cold traps in series. The first trap is maintained at 10 C. and the second trap at 80 C. The reaction flask is heated to, and maintained at, 250 C., while hexafluoropropylene epoxide is passed through the vigorously stirred benzophenoue at 80 ml. per minutes, for about 5 hours. The product in both traps is combined and the perfluoropyruvyl fluoride obtained by fractional distillation.

In concentrated form and in the presence of fluoride ions, perfluoropyruvyl fluoride dimerized to COF GE' -CE o- -oF= The dimer can be obtained directly by carrying out the hexafluoropropylene epoxide reaction at higher pressures. For example, g. of benzophenoue and 137 g. of hexa fiuoropropylene epoxide heated at C. for 4 hours in a 330 cc. stainless steel lined autoclave will result in direct preparation of the dimer.

As many apparently widely different embodiments of this invention may be made without departing from the spirit and scope thereof, it is to be understood that this invention is not limited to the specific embodiments thereof except as defined in the appended claims.

What is claimed is:

1. A homopolymer having recurring units of the formula OR -CF2-(J wherein R is alkyl containing up to 30 carbon atoms.

2. The homopolymer of claim 1 in the form of a film. 3. A homopolymer having recurring units of the formula --CF2--C|3- 00113 4. The homopolymer of claim 3 in the form of a film. 5. A homopolymer having recurring units of the formula OCHzCHa OCHZCH3 6. The homopolymer of claim 5 in the form of a film. 7. A copolymer consisting of recurring units of the formulas (I)R -CF2(i) 2 OR and CF -CF wherein R is alkyl containing up to 30 carbon atoms.

8. The copolymer of claim 7 in the form of a film. 9. A copolymer consisting of recurring units of the formulas 10. The copolymer of claim 9 in the form of a film. 11. A copolymer consisting of recurring units of the formulas and 0 CHaCH -C Fz-C 0 0112011 and --CF CF 12. The copolymer of claim 11 in the form of a film. 13. A polymer of difiuoroketene dialkyl acetal consisting of recurring units of the formula 0R C Fg-- 6R wherein R is alkyl containing up to 30 carbon atoms.

References Cited UNITED STATES PATENTS 2,689,241 9/1954 Pittman 26087.5

JOSEPH L. SCHOFER, Primary Examiner JOHN A. DONAHUE, JR., Assistant Examiner U.S. Cl. X.R. 

